Prefabricated building section with wall,floor and ceiling components cast in profiled edge beams



May 6, 1969 c. VAN DER LELY ETAL 3,442,056 PREFABRICATED BUILDING SECTION WITH WALL, FLQOR, AND CEILING COMPONENTS CAST IN PROPOFILED EDGE BEAM Filed March 2, 1966 Sheet of 4 INVENTORS Cop/v61 IS VAN 05!? A EL V Elm/01:21am a/Acoeus Cog /vg /s Meuwmvuovr-r/v May 6, 1969 c. VAN DER LELY ETAL 3,442,056

PREFABRICATED BUILDING SECTION WITH WALL, FLOOR, AND CEILING COMPONENTS CAST IN PROFILED EDGE BEAMS Filed March 2. 1966 Sheet 2 of 4 INVENTORS COIQNEL 15 VA N 05p [51. V

HENDAP/CUS Jiwoau CB QNEL/J MEUNENHOVEN May 6, 1969 c. VAN DER LELY ETAL 3,442,056

PREFABRICATED [5U ILIJiNG SECTION WITH WALL. FLOOR, AND CEILING COMPONENTS CAST IN PROFILED EDGE BEAMS Filed March 2, 1966 Sheet of 4 win INVENTORS COQ/VEL/j VAN 0E4 [ELY HE/VOP/CUJ dicoaus B $NELIS Msuh avuovs/v May 6, 1969 c. VAN DER LELY ETAL 3,442,056

PREFABRICATED BUILDING SECTION WITH WALL. FLOOR, AND

031mm; COMPONENTS CAST IN PROFILED EDGE BEAMS Filed March 2, 1966 Sheet 4 of 4 INVENTORS COAA/EL/S VA: 050 EL 5 Hnvamcus L/A c 0 61/6 CBbYQ/VEL /5 N/EUWENHOVEN United States Patent US. Cl. 5279 8 Claims SABSTRACT OF THE DISCLOSURE A prefabricated building unit wherein the wall, floor and ceiling components have profiled metal beam frames such as U-beam frames and a castable material such as concrete is cast in the frames. The components are welded or otherwise secured together to form a parallelepiped unit. Deformable material may be used to fill open spaces or on the floor component when the components are secured together. 'Frame beams are 'U-shaped with a smaller U-shaped beam therein, the legs of each terminating in the same area with continuous or interrupted spaces therebetween adapted to receive and hold the cast material. Inward extensions from the frame beams extend into the cast material.

Summary of the invention The invention relates to a prefabricated section for a building, the section having a wall portion, a floor portion and a ceiling portion.

The invention has for its object to provide a strong section that can be manufactured within a short time and at low costs It is intended for a building which can be erected in a simple manner by one or more of these sections.

According to the invention, there is provided a prefabricated section for a building, the section having a wall portion, a floor portion and a ceiling portion, one or more walls of the section being constituted by profiled metal beams between which material is cast, said profiled metal beams being secured to further profiled metal beams arranged in or on the floor or the ceiling, or both, of the section.

Brief description of the drawing For a better understanding of the invention and to show how the same may be readily carried into etfect, reference is made by way of example to the accompanying drawings, in which:

FIGURE 1 is a perspective view of a building forming a bungalow comprising prefabricated sections according to the invention,

FIGURE 2 is the FIGURE 1,

FIGURE 3 is an expanded view showing diagrammatically the parts which will be assembled to form a section of the bungalow shown in FIGURE 1,

FIGURE 4 is a perspective view of the parts shown in FIGURE 3 joined to form the section,

FIGURE 5 shows a wall of a section provided with a door frame,

FIGURE 6 is a fragmentary and broken perspective view in enlarged scale of a detail of the section shown in FIGURE 4,

FIGURE 7 is a horizontal section showing two forms of beam in the walls of two adjacent sections,

plan of the bungalow shown in 3,442,056 Patented May 6, 1969 FIGURE 8 is an elevation taken on the line VIII--VIII of FIGURE 7,

FIGURE 9 is an elevation taken on the line IX-IX in FIGURE 7,

FIGURE 10 is a horizontal section showing two further forms of beam in the walls of two adjacent sections, and

FIGURE 11 is a vertical section taken on the line XI-XI in FIGURE 10.

Description of preferred embodiments Referring to FIGURES 1 and 2, the bungalow comprises five sections 1, 2, 3, 4 and 5, each of which encloses part of the overall space of the bungalow and includes of a wall portion, a floor portion and a ceiling portion, the latter forming part of the roof of the bungalow.

FIGURE 3 shows the parts of the section 1, consisting of a floor 6, walls 7, 8, 9, 10 and 11 and a ceiling 12. The floor 6, the walls 7, 8, 9, 10 and 11 and the ceiling 12 are first manufactured separately and subsequently joined to each other to form the section shown in FIG- URE 4.

The floor 6 comprises four beams 13, 14, 1-5 and 16, forming a rectangular frame along the periphery of the floor. The beams 13 and 15 are parallel to each other, as are the beams 14 and 16. The section 1 is a parallelepiped, the floor 6 having two long beams 13 and 15 and two short beams 14 and 16. The beams 13, 14, 15 and 16 are channel-section metal beams, the beams 14 and 16 being in contact with the beams 13 and 15 inside the limbs of the latter (see FIGURE 6). Between the beams 13, 14, 15 and 16 the floor comprises a concrete plate 17 (see FIGURE 6) which is cast between the beams 13, 14, 1-5 and -16.

Each of the walls 7, 8, 9, 10 and 11 has two vertical profiled metal beams such as, for example, beams 18 and 19 of wall 11, between which a plate of concrete such as, for example, plate 20 (see FIGURE '6) is provided by casting. The concrete plate 20 is cast between the beams 18 and 19 in such a manner that after hardening of concrete said beams are afiixed to plate 20. It may be advantageous for this purpose to provide a channel-section profile of the beams, so that the edges of plate 20- are held between the limbs of the channel-section beams. The beams 18 and 19 may be formed with a channelsection shape or be provided with extensions so that the connection between the beams 18 and 19 and the plate 20 is stiffened, as will be described more fully hereinafter with reference to FIGURES 7 to 11. The walls 7, 8, 9 and 10 are constructed like the wall 11, so that a further description thereof is unnecessary.

Referring to FIGURES 3 to 6, the ceiling 12 has two long beams 21 and 22 at the periphery and two short beams 23 and 24, lying between the former. The further part of the ceiling is fixed to the beams 21 to 24 so that the upper side forms a substantially finished portion of the roof of the bungalow, whereas the lower interior side is constructed so that it can be finished according to the various spaces (not shown) of the section concerned. After the floor 6, the walls 7, 8, 9, 10 and 11 and the ceiling 12 have been manufactured, they are secured to each other. First the walls 7, 8, 9, 10 and 11 and the floor 6 may be secured to each other. The beams 18 on the vertical sides of the walls are welded to the profiled metal beams along the edges of the floor 6. While the walls are secured to the floor, a layer of material 25 (see FIGURE 6) is provided between the lower side of the wall and the upper side of the floor. The layer 25 is deformable so that cracks between the wall and the floor are filled up. The material of the layer 25 may be such that it hardens after mounting. However, as an alternative, material which remains elastic may be employed. If desired, the layer 25 may be omitted and cracks, if any, between the lower sides of the walls and the upper side of the floor may be stuifed in a different manner. After the walls 7, 8, 9, and 11 and the floor 6 have been joined, the ceiling 12 can be arranged on the upper sides of the walls 7, 8, 9, 10 and 11. The beams 21, 22, 23 and 24 of the ceiling 12 are welded to the upper sides of the vertical beams 18 and 19 of the walls 7, 8, 9, 10 and 11. If desired, stops (not shown) may be arranged on the lower side of the ceiling 12 for engagement with the upper sides of the walls 7, 8, 9, 10 and 11 so that these stops determine the correct positions of the walls 7, 8, 9, 10 and 11 to the lower side of the ceiling.

Although, as described above, first the walls are secured to the floor and subsequently the roof is arranged on the upper sides of the walls, it is possible to arrange first the roof on the upper sides of the walls and afterwards to fasten the lower sides of the walls to the floor 6.

The further sections are prefabricated like the section 1. Thus, in the case of sections 2, 3, 4- and 5, the walls, the floor and the ceiling are manufactured separately, these parts being subsequently secured to each other. The connection of the metal profiled beams of the walls, the floor and the ceiling provides a strong, rigid section which can be transported easily to the building site after the prefabrication, for example, in the workshop, on which site the building can be erected from one or more sections. With those sections in which the walls join each other, first the walls may be secured to each other, after which the interconnected walls are secured to the floor and the ceiling.

If a door has to be provided in a wall of a section, the door frame may be arranged therein when the wall is cast. FIGURE 5 shows a wall 26, in which a door frame 27 is provided. This wall 26 may form part of the section 2, which is shown in FIGURE 2. When the wall is formed in a jig, the beams 28 and 29 and the door frame 27 may be arranged therein. After these beams and the door frame have been arranged in place in the jig, concrete can be cast into the jig, so that a fixed connection between the beams, the door frame and the concrete is obtained. Although this is not shown in detail in FIG- URE 5, the door frame 27 may have such a shape that it is satisfactorily anchored in the concrete. To this end if desired, iron anchors may be secured to the door frame.

In order to obtain light-weight walls of the sections, they may be made of light-weight concrete. In principle, the walls may be made of materials other than concrete.

FIGURE 7 shows two beams 30 and 31, which form vertical beams of adjacent walls of neighboring sections. The vertical beam 30 consists of two substantially U- shaped strips 32 and 33, the U-shaped strip 33 being arranged between limbs 34 and 35 of the U-shaped strip 32. A web 36 of the U-shaped strip 32 has a V-shaped portion 37, pointing towards the interior of the beam 30. The V-shaped portion 37 extends throughout the length of the beam 30. The U-shaped strip 33 has two limbs 38 and 39 and a web 40. The ends of the limbs 38 and 39 are approximately even with the ends of the limbs 34 and 35. In order to obtain a satisfactory anchorage of the beam 30 in concrete plate 41 of the wall concerned, the limbs 38 and 39 are provided throughout their lengths with spaced portions 42, curved towards each other (FIGURE 9). Cavities 43 for accommodating the concrete of the wall 41 are thus formed between the limbs 34 and 35 of the U-shaped strip 32 and the limbs 38 and 39 of the U-shaped strip 33. This provides a satisfactory connection between the beam 30 and the concrete 41.

The beam 31 is shaped substantially in the same form as the beam 30 and corresponding parts are therefore designated by the same reference numerals. In the embodiment of the beam 31, however, the limbs 38 and 39 have inwardly bent-over ends throughout the length (see FIGURE 8). Thus a V-shaped recess 44 for accommodating the concrete of the wall 45 is formed between the limbs 38 and 39 and the limbs 34 and 35 so that the beam 31 is satisfactorily anchored in the concrete plate 45 of the wall concerned. When the sections comprising the beams 30 and 31 are joined, a filling substance 46 is provided between the beams 31 and 30 in the V-shaped recess 37 of said beams.

FIGURES 10 and 11 show beams 47 and 48 of joined walls of adjacent sections. The beams '47 and 48 are again formed by U-shaped strips 49 and 50. In this embodiment the webs 51 of the U-shaped strips 49 are flat so that the beams join each other by these flat sides. The web 52 of the U-shaped strip 50 is provided with tags 53, which are bent over out of the web 52. The tags 53 have a bentover end 54. The tags 53 provide a satisfactory anchorage of the beam 47 in the concrete plate 55 of the wall. Various tags 53 may be provided throughout the length of the beam 47 at given distances from each other. In order to avoid concrete from penetrating through the openings 56 into the interior of the beam 47, these openings may be closed when the concrete is cast; for example, a beam may be fitted in the interior of the beam 47. The beam 48 has differently shaped extensions, which are held in concrete plate 57 and provide a satisfactory anchorage of the beam 48 in the concrete plate 57. The beam 48 is provided with hooks 58, having bent-over ends 59. In the embodiment shown in FIGURES 10 and 11, the hooks 58 lying one above the other, are alternately arranged so that the bent-over portions 59 are orientated to different sides, in the concrete plate 57. The embodiments shown in FIGURES 7 to 11 may all be employed as U-shaped profiled beams in the walls of prefabricated sections.

The walls of the sections described above may be provided, after the floor and the roof have been arranged in place, with a coating, for example wall paper so that each prefabricated section is completely finished before it is joined to further sections to form the bungalow.

When the sections are intended for use in a multistory building, the ceiling side of the sections will be adapted to this purpose. The upper side of a section which will have a section of a higher story arranged thereon need then not have a roof portion of the building, while, the ceiling must be suitable for arranging the section of the higher story thereon. By forming separately the floor, the walls and the ceiling before joining them to each other, the manufacture can be carried out quickly. Although the metal beams of the walls, the floor and the ceiling are welded to each other, they may, in principle, be secured to each other in a different manner.

It will be understood that in another form of the invention, only one of the walls of the section is provided with the profiled metal beams.

Having thus described our invention, what we claim as new and desire to secure by Letters Patent of the United States is:

1. A prefabricated section for a building, the section comprising a wall portion, a floor portion and a ceiling portion, at least one wall portion of the section comprising profiled metal beams between which concrete material is cast, further profiled metal beams in said floor portion and said ceiling portion forming a rectangular framework about the edge of their respective portions, the first mentioned profiled metal beams being secured to said further profiled metal beams, said first mentioned profiled beams being formed by two U-shaped metal strips, one strip being fitted between the limbs of the other U-shaped strip, with the limbs of the two strips extending in the same direction, extensions from the inner of said strips embedded in said concrete.

2. A prefabricated section for a building, said section having wall portions, a floor portion and a ceiling portion, at least one of said wall portions of said section comprising profiled metal beams at opposite vertical sides, said beams having a rectangularly shaped hollow part and inward extensions and at least two parallel limbs extending away from said hollow part, cast concrete material received in secured engagement between said limbs, said inward extensions from said hollow part embedded in said material, said profiled metal beams being fiat on their edges opposite said cast material received in said limbs, further profiled metal beams in said floor portion and in said ceiling portion, the first mentioned of said profiled beams being secured to said further profiled beams.

3. A prefabricated section for a building, the section comprising a wall portion, a floor portion and a ceiling portion, at least one wall portion of the section comprising profiled metal beams between which material is cast, further profiled metal beams in said floor portion and said ceiling portion, the first mentioned profiled metal beams being secured to said further profiled metal beams, said floor portion situated between said profiled metal beams comprising cast concrete, said profiled metal beams being each formed by two U-shaped metal strips, one strip being fitted between the limbs of the other U-shaped strip, with the limbs of the two strips extending in the same direction.

4. A section as claimed in claim 3, wherein the web of the outer U-shaped strip is provided with a groove.

5. A prefabricated section for a building, the section comprising a wall portion, a floor portion and a ceiling portion, at least one wall portion of the section comprising profiled metal beams between which material is cast, further profiled met-a1 beams in said floor portion and said ceiling portion, the first mentioned profiled metal beams being secured to said further profiled metal beams, said first mentioned profiled beams being formed by two U-shaped metal strips, one strip being fitted between the limbs of the other U-shaped strip, with the limbs of the two strips extending in the same direction, the limbs of the the inner U-shaped strip being corrugated in the direction of length of the beam whereby par-ts of the limbs of the inner U-shaped strip are alternately in contact with the limbs of the outer strip and are at a distance therefrom.

6. A prefabricated section for a building, the section comprising a wall portion, a floor portion and a ceiling portion, at least one wall portion of the section comprising profiled metal beams between which material is cast, further profiled metal beams in said floor portion and said ceiling portion, the first mentioned profiled metal beams being secured to said further profiled metal beams, said first mentioned profiled beams being formed by two U-shaped metal strips, one strip being fitted between the limbs of the other U-shaped strip, with the limbs of the two strips extending in the same direction, the ends of the limbs of the inner U-shaped strip being bent over inwardly throughout the length of the beam.

7. A prefabricated section for a building, the section comprising a wall portion, a floor portion and a ceiling portion, at least one wall portion of the section comprising profiled metal beams between which material is cast, further profiled metal beams in said floor portion and said ceiling portion, the first mentioned profiled metal beams being secured to said further profiled metal beams, said first mentioned profiled beams being formed by two U-shaped metal strips, one strip being fitted between the limbs of the other U-shaped strip, with the limbs of the two strips extending in the same direction, the web of the inner U-shaped strip provided with inwardly extending extensions.

8. A section as claimed in claim 7, wherein said extensions are formed by portions bent out of the web of the inner U-shaped strip.

References Cited UNITED STATES PATENTS 1,796,048 3/1931 Robinson 52-221 X 2,151,148 3/1939 Plumb 52-601 X 2,270,672 1/1942 Heeren 52-601 2,238,355 4/1941 Whitenack 52-601 2,462,415 2/1949 Nagel 52-601 X 2,664,740 1/ 1954 Cochrane 52-601 X 2,691,291 10/1954 Henderson 52-79 X 2,934,934 5/1960 Berliner 52-601 2,969,619 1/1961 Didrick 52-601 3,243,929 4/1966 Strandlund et a1. 52-615 X ALFRED C. PERHAM, Primary Examiner.

US. Cl. XJR. 52-236, 586, 601 

